Anti-reflection coating, optical member, exchange lens unit and imaging device

ABSTRACT

An anti-reflection coating comprising first to seventh layers formed on a substrate in this order, the first layer being an alumina-based layer, the seventh layer being a porous, silica-based layer, and each of the first to seventh layers having predetermined refractive index and optical thickness in a wavelength range of 400-700 nm.

FIELD OF THE INVENTION

The present invention relates to an anti-reflection coating suitable for exchange lens units for single-lens reflex cameras, etc., an optical member comprising such an anti-reflection coating, and an exchange lens unit and an imaging device comprising such an optical member.

BACKGROUND OF THE INVENTION

A high-performance, single-focus or zoom lens unit for single-lens reflex cameras, etc. generally has about 10-40 lenses in a lens barrel. Each lens has a laminated anti-reflection coating comprising pluralities of dielectric layers each having a different refractive index from that of a lens substrate and a thickness of ½λ or ¼λ, wherein λ is a center wavelength, to utilize interference effects. The anti-reflection characteristics are important to a wide-angle lens, to which the angle of incident light is large particularly in its peripheral portion.

For instance, when an anti-reflection coating formed on each of 20 lenses has reflectance of 0.5%, its transmittance is 0.995⁴⁰=0.818 because the number of lens surfaces is 40, resulting in reflection loss of about 18%. Because reflection is superimposed in and between the lenses, large reflection loss of each lens provides the resultant photographs with flare and ghost, as well as reduced contrast. Accordingly, an anti-reflection coating with small reflection loss should be formed on a lens used in single-focus or zoom lens units.

In addition, blue tarnish, white tarnish, etc. may occur on the surface of a lens during a production process. The blue tarnish is a thin film formed by basic components in optical glass dissolved into dew attached to a surface of the optical glass left in the air, or water during a grinding step. The white tarnish is white blot generated by the chemical reaction of components eluted from the glass. Accordingly, the anti-reflection coating formed on a glass lens should have a function to prevent tarnish.

JP 5-85778 A discloses an optical member comprising an anti-reflection coating having pluralities of dielectric layers on an optical substrate, the innermost layer being made of SiO_(x) (1≦x≦2) and having a thickness nd of 0.25λ₀ or more, wherein λ₀ is a designed wavelength. However, this anti-reflection coating has poor anti-reflection performance, and fails to fully prevent tarnish.

JP 10-20102 A discloses an anti-reflection coating comprising first to seventh layers formed in this order on a substrate having a refractive index of about 1.4-1.9 at a reference wavelength λ₀ arbitrarily designed in a visible wavelength range, the first to seventh layers meeting the following conditions: 1.35≦n₁≦1.80, 1.90≦n₂≦2.50, 1.35≦n₃≦1.80, 1.90≦n₄≦2.50, 1.35≦n₅≦1.80, 1.90≦n₆≦2.50, 1.35≦n₇≦1.50, 0.0450λ₀≦n₁d₁≦0.2500λ₀, 0.0450λ₀≦n₂d₂≦0.1300λ₀≦0.0450λ₀≦n₃d₃≦0.1100λ₀, 0.2100λ₀≦n₄d₄≦0.3000λ₀, 0.0450λ₀≦n₅d₅≦0.0750λ₀, 0.1000λ₀≦n₆d₆≦0.1600λ₀, 0.2350λ₀≦n₇d₇≦0.2900λ₀, wherein n₁-n₇ are the refractive indices of the first to seventh layers, and n₁d₁-n₇d₇ are the optical thickness of the first to seventh layers. Although this anti-reflection coating has a tarnish-preventing function because the first layer is made of alumina, its reflectance to visible light is as large as about 0.3% because the seventh layer is made of MgF₂.

JP 2001-100002 A discloses an anti-reflection coating having a 10-layer structure comprising a MgF₂ layer, a ZrO₂/TiO₂ layer, an Al₂O₃ layer, a SiO₂ layer, a ZrO₂/TiO₂ layer, a SiO₂ layer, a ZrO₂/TiO₂ layer, a SiO₂ layer, a ZrO₂/TiO₂ layer, and an Al₂O₃ layer in this order from the surface, which has reflectance of about 0.1% at a visible wavelength of 270 nm. JP2002-107506 A discloses an anti-reflection coating having a 10-layer structure comprising a MgF₂ layer, a ZrO₂/TiO₂ layer, a SiO₂ layer, an Al₂O₃ layer, a ZrO₂/TiO₂ layer, a SiO₂ layer, a ZrO₂/TiO₂ layer, a SiO₂ layer, a ZrO₂/TiO₂ layer, and an Al₂O₃ layer in this order from the surface, which has reflectance of about 0.1% at a visible wavelength of 300 nm. However, because of the outermost MgF₂ layer having as high a refractive index as 1.38, both anti-reflection coatings should have as many as 10 layers for sufficient anti-reflection characteristics.

JP 2005-352303 A discloses an anti-reflection coating comprising pluralities of layers each having a physical thickness of 15-200 nm, which are formed on a substrate such that their refractive indices decrease gradually from the substrate side, the refractive index difference between adjacent layers and between the innermost layer and the substrate being 0.02-0.2, and the outermost layer being a silica aerogel layer. However, it has as large reflectance as more than 0.5% to visible light near a wavelength of 400 nm, and fails to fully prevent tarnish.

JP 2006-3562 A discloses an anti-reflection coating comprising pluralities of layers each having a physical thickness of 15-200 nm, which are formed on a substrate such that their refractive indices decrease gradually from the substrate side, the refractive index difference between adjacent layers and between the innermost layer and the substrate being 0.02-0.2, the innermost layer being an alumina layer, and the outermost layer being a silica aerogel layer. Although this anti-reflection coating has a tarnish-preventing function because the innermost layer is made of alumina, it does not have sufficient reflectance to visible light near a wavelength of 400 nm.

JP 2007-94150 A discloses an anti-reflection coating having 5 or 6 layers, the outermost layer being a silica aerogel layer, which has reflectance of 0.05% or less to visible light in a wavelength range of 400-700 nm at an incident angle of 5°. However, because the innermost layer is made of Ta₂O₅ or ZrO₂, tarnish cannot be fully suppressed unlike alumina.

OBJECT OF THE INVENTION

Accordingly, an object of the present invention is to provide an anti-reflection coating having excellent anti-reflection characteristics without suffering tarnish, an optical member having such an anti-reflection coating, and an exchange lens unit and an imaging device comprising such an optical member.

DISCLOSURE OF THE INVENTION

Thus, the first anti-reflection coating of the present invention comprises first to seventh layers formed on a substrate in this order, the first layer being an alumina-based layer, the seventh layer being a porous, silica-based layer, and in a wavelength range of 400-700 nm,

-   -   the substrate having a refractive index of 1.60-1.95,     -   the first layer having an optical thickness of 37.5-112.5 nm,     -   the second layer having a refractive index of 1.95-2.25 and an         optical thickness of 35.5-60.0 nm,     -   the third layer having a refractive index of 1.35-1.50 and an         optical thickness of 24.5-41.5 nm,     -   the fourth layer having a refractive index of 1.95-2.25 and an         optical thickness of 210.5-250.0 nm,     -   the fifth layer having a refractive index of 1.35-1.50 and an         optical thickness of 12.5-32.5 nm,     -   the sixth layer having a refractive index of 1.95-2.25 and an         optical thickness of 27.5-45.0 nm, and     -   the seventh layer having an optical thickness of 108.0-138.0 nm.

In the first anti-reflection coating, the second layer, the fourth layer and the sixth layer are preferably made of at least one material selected from the group consisting of Ta₂O₅, ZrO₂, HfO₂, CeO₂, SnO₂, In₂O₃ and ZnO, and the third layer and the fifth layer are preferably made of MgF₂ and/or SiO₂. At least one material selected from the group consisting of TiO₂, Nb₂O₅, Y₂O₃ and Pr₆O₁₁ may be added to the second layer, the fourth layer and the sixth layer. Al₂O₃ may be added to the third layer and the fifth layer.

In the first anti-reflection coating, the first layer preferably has a refractive index of 1.59-1.69, and the seventh layer preferably has a refractive index of 1.25-1.30.

The first anti-reflection coating preferably has reflectance of 0.5% or less to incident light at 0° in a wavelength range of 450-600 nm, and reflectance of 1.0% or less to incident light at 30° in a wavelength range of 400-650 nm.

The second anti-reflection coating of the present invention comprises first to seventh layers formed on a substrate in this order, the first layer being an alumina-based layer, the seventh layer being a porous, silica-based layer, and in a wavelength range of 400-700 nm,

-   -   the substrate having a refractive index of 1.50-1.70,     -   the first layer having an optical thickness of 24.5-200.0 nm,     -   the second layer having a refractive index of 1.93-2.25 and an         optical thickness of 24.5-50.5 nm,     -   the third layer having a refractive index of 1.33-1.50 and an         optical thickness of 14.0-30.0 nm,     -   the fourth layer having a refractive index of 2.00-2.16 and an         optical thickness of 131.5-200.5 nm,     -   the fifth layer having a refractive index of 1.33-1.50 and an         optical thickness of 20.0-31.5 nm,     -   the sixth layer having a refractive index of 2.04-2.17 and an         optical thickness of 50.0-62.5 nm, and     -   the seventh layer having an optical thickness of 122.5-142.5 nm.

In the second anti-reflection coating, the second layer, the fourth layer and the sixth layer are preferably made of at least one material selected from the group consisting of Ta₂O₅, ZrO₂, HfO₂, CeO₂, SnO₂, In₂O₃ and ZnO, and the third layer and the fifth layer are preferably made of MgF₂ and/or SiO₂. At least one material selected from the group consisting of TiO₂, Nb₂O₅, Y₂O₃ and Pr₆O₁₁ may be added to the second layer, the fourth layer and the sixth layer. Al₂O₃ may be added to the third layer and the fifth layer.

In the second anti-reflection coating, the first layer preferably has a refractive index of 1.57-1.72, and the seventh layer preferably has a refractive index of 1.23-1.32.

The second anti-reflection coating has reflectance of 0.3% or less to incident light at 0° in a wavelength range of 450-600 nm.

In the first and second anti-reflection coatings, the seventh layer is preferably a silica aerogel layer.

In the first and second anti-reflection coatings, a fluororesin layer as thick as 0.4-100 nm having water repellency or water/oil repellency is preferably formed on the seventh layer.

In the first and second anti-reflection coatings, the first to sixth layers are preferably formed by a physical vapor deposition method, and the seventh layer is preferably formed by a wet method. The physical vapor deposition method is preferably a vacuum vapor deposition method, and the wet method is preferably a sol-gel method.

The optical member of the present invention comprises the above anti-reflection coating. The exchange lens unit of the present invention comprises the above optical member. The imaging device of the present invention comprises the above optical member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view showing the anti-reflection coating formed on a substrate according to one embodiment of the present invention.

FIG. 2 is a cross-sectional view showing the anti-reflection coating formed on a substrate according to another embodiment of the present invention.

FIG. 3 is a graph showing the spectral reflectance of the anti-reflection coating of Example 1.

FIG. 4 is a graph showing the spectral reflectance of the anti-reflection coating of Example 2.

FIG. 5 is a graph showing the spectral reflectance of the anti-reflection coating of Example 3.

FIG. 6 is a graph showing the spectral reflectance of the anti-reflection coating of Example 4.

FIG. 7 is a graph showing the spectral reflectance of the anti-reflection coating of Example 5.

FIG. 8 is a graph showing the spectral reflectance of the anti-reflection coating of Comparative Example 1.

FIG. 9 is a graph showing the spectral reflectance of the anti-reflection coating of Example 7.

FIG. 10 is a graph showing the spectral reflectance of the anti-reflection coating of Example 8.

FIG. 11 is a graph showing the spectral reflectance of the anti-reflection coating of Example 9.

FIG. 12 is a graph showing the spectral reflectance of the anti-reflection coating of Comparative Example 2.

FIG. 13 is a schematic view showing an example of apparatuses for forming the anti-reflection coating.

DESCRIPTION OF THE PREFERRED EMBODIMENTS [1] First Anti-Reflection Coating

(1) Layer Structure of Anti-Reflection Coating

The first anti-reflection coating 1 according to one embodiment of the present invention comprises, as shown in FIG. 1, first to seventh layers 11-17 formed on a substrate 3 in this order. The first layer 11 is based on alumina, and the seventh layer 17 is a porous, silica-based layer. In a wavelength range of 400-700 nm,

the substrate 3 has a refractive index of 1.60-1.95,

the first layer 11 has an optical thickness of 37.5-112.5 nm,

the second layer 12 has a refractive index of 1.95-2.25 and an optical thickness of 35.5-60.0 nm,

the third layer 13 has a refractive index of 1.35-1.50 and an optical thickness of 24.5-41.5 nm,

the fourth layer 14 has a refractive index of 1.95-2.25 and an optical thickness of 210.5-250.0 nm,

the fifth layer 15 has a refractive index of 1.35-1.50 and an optical thickness of 12.5-32.5 nm,

the sixth layer 16 has a refractive index of 1.95-2.25 and an optical thickness of 27.5-45.0 nm, and

the seventh layer 17 has an optical thickness of 108.0-138.0 nm,

wherein the optical thickness=refractive index×physical thickness.

The refractive index of the alumina-based first layer 11 is preferably 1.59-1.69, more preferably 1.63-1.67. The first layer 11 preferably has an optical thickness of 60.0-100.0 nm. Alumina has particularly high adhesion to a glass substrate, high transmittance in a wide wavelength range, high hardness, excellent wear resistance, and good cost efficiency. Because alumina has excellent shielding to water vapor, the alumina-based first layer 11 can prevent tarnish on the surface of the substrate 3.

The seventh layer 17 is preferably made of a silica aerogel to provide a low refractive index and an excellent anti-reflection function. The refractive index of the seventh layer 17 is preferably 1.25-1.30, more preferably 1.26-1.29. The porous seventh layer 17 preferably has a pore diameter of 0.005-0.2 μm, a porosity of 20-60%, and an optical thickness of 115.0-138.0 nm. The seventh layer 17 made of a silica aerogel may be hydrophobized. The hydrophobized silica aerogel layer has excellent water resistance and durability.

The second layer 12 preferably has an optical thickness of 36.0-52.0 nm and a refractive index of 2.02-2.20. The third layer 13 preferably has an optical thickness of 27.0-37.0 nm and a refractive index of 1.36-1.45. The fourth layer 14 preferably has an optical thickness of 210.0-247.0 nm and a refractive index of 2.00-2.15. The fifth layer 15 preferably has an optical thickness of 17.0-25.0 nm and a refractive index of 1.36-1.45. The sixth layer 16 preferably has an optical thickness of 32.0-43.0 nm and a refractive index of 2.00-2.20.

(2) Materials

The first layer 11 is based on alumina (aluminum oxide), whose purity is preferably 99% or more by mass. Any of the second layer 12, the fourth layer 14 and the sixth layer 16 is preferably made of at least one material selected from the group consisting of Ta₂O₅, ZrO₂, HfO₂, CeO₂, SnO₂, In₂O₃ and ZnO. Any of the third layer 13 and the fifth layer 15 is preferably made of MgF₂ and/or SiO₂. At least one material selected from the group consisting of TiO₂, Nb₂O₅, Y₂O₃ and Pr₆O₁₁ may be added to the second layer 12, the fourth layer 14 and the sixth layer 16. Al₂O₃ may be added to the third layer 13 and the fifth layer 15. The seventh layer 17 is based on silica, which is preferably silica aerogel.

(3) Production Method

[a] Formation Method of First to Sixth Layers

The first layer 11 to the sixth layer 16 are preferably formed by a physical vapor deposition method such as a vacuum vapor deposition method, a sputtering method, etc., particularly a vacuum vapor deposition method from the aspect of a production cost and precision.

The vacuum vapor deposition method may be a resistor-heating type, an electron-beam type, etc. The electron-beam vacuum vapor deposition method will be explained below referring to a vacuum vapor deposition apparatus 30 shown in FIG. 13. The vacuum vapor deposition apparatus 30 comprises, in a vacuum chamber 31, a rotatable rack 32 for carrying pluralities of lenses on its inner surface, a vapor source 33 comprising a crucible 36 containing an evaporating material, an electron beam irradiator 38, a heater 39, and a vacuum pump connector 35 connected to a vacuum pump 40. To form the first to sixth layers in the first anti-reflection coating 1 on each lens 100, the lens 100 is attached to the rotatable rack 32 such that its surface is oriented to the vapor source 33, and the evaporating material 37 is placed in the crucible 36. After the vacuum chamber 31 is evacuated by the vacuum pump 40 connected to the vacuum pump connector 35, the lens 100 is heated by the heater 39. While rotating the rotatable rack 32 by a shaft 34, electron beams are irradiated from the electron beam irradiator 38 to the evaporating material 37 to heat it. The vaporized material 37 is deposited on the lens 100, so that each layer in the first anti-reflection coating 1 is formed on the lens 100.

In the vacuum vapor deposition method, the initial degree of vacuum is preferably 1.0×10⁻⁵ Torr to 1.0×10⁻⁶ Torr. When the degree of vacuum is less than 1.0×10⁻⁵ Torr, insufficient vapor deposition occurs. When the degree of vacuum is more than 1.0×10⁻⁶ Torr, it takes too much time for vapor deposition, resulting in poor production efficiency. To increase the precision of the formed layers, it is preferable to heat the lens during vapor deposition. The lens temperature during vapor deposition may be properly determined based on the heat resistance of the lens and the vapor deposition speed, but it is preferably 60-250° C.

[b] Formation Method of Seventh Layer

(i) Preparation of Organically Modified Silica Dispersion

(i-1) Formation of Wet Gel

The wet gel is formed by dissolving a silica-skeleton-forming compound and a catalyst in a solvent, causing the hydrolysis and polymerization of the silica-skeleton-forming compound, and then conducting aging.

(a) Silica-Skeleton-Forming Compound

(a-1) Saturated alkoxysilane and silsesquioxane

Silica sol and gel are formed by the hydrolysis and polymerization of alkoxysilane and/or silsesquioxane. The saturated alkoxysilane may be a monomer or an oligomer. The saturated alkoxysilane monomer preferably has 3 or more alkoxy groups. Using a saturated alkoxysilane having 3 or more alkoxy groups as a silica-skeleton-forming compound, anti-reflection coatings with excellent uniformity can be obtained. Specific examples of the saturated alkoxysilane monomers include methyltrimethoxysilane, methyltriethoxysilane, phenyltriethoxysilane, tetramethoxysilane, tetraethoxysilane, tetrapropoxysilane, tetrabutoxysilane, diethoxydimethoxysilane, dimethyldimethoxysilane, and dimethyldiethoxysilane. The saturated alkoxysilane oligomers are preferably polycondensates of these monomers. The saturated alkoxysilane oligomers can be obtained by the hydrolysis and polymerization of the monomers.

The use of a saturated silsesquioxane as a silica-skeleton-forming compound can also provide an anti-reflection coating with excellent uniformity. The saturated silsesquioxane is a general name of polysiloxanes in the form of network, which have structural units represented by the general formula: RSiO_(1.5), wherein R represents an organic functional group. R may be, for instance, a linear or branched alkyl group having 1-6 carbon atoms, a phenyl group, or an alkoxy group (a methoxy group, an ethoxy group, etc.). It is known that the silsesquioxane has various structures such as a ladder structure, a cage structure, etc. It has excellent weather resistance, transparency and hardness, suitable as a silica-skeleton-forming compound for the silica aerogel.

(a-2) Unsaturated Alkoxysilane Monomer and Silsesquioxane

An unsaturated monomer or oligomer of alkoxysilane or silsesquioxane having an ultraviolet-polymerizable unsaturated group may be used as a silica-skeleton-forming compound. Using the silica-skeleton-forming compound having an unsaturated group, a silica aerogel coating with excellent toughness can be obtained even when a small amount of a binder is added. The unsaturated alkoxysilane monomer has an organic group having at least one double or triple bond (hereinafter referred to as “unsaturated group”), and an alkoxy group. The unsaturated group has 2-10 carbon atoms, preferably 2-4 carbon atoms.

The preferred unsaturated alkoxysilane monomer is represented by the following general formula (1); R^(a)Si(OR^(b))₃  (1), wherein R^(a) represents an organic group having an unsaturated bond and 2-10 carbon atoms, and R^(b)O represents an alkoxy group having 1-4 carbon atoms.

The unsaturated group R^(a) is an organic group having at least one ultraviolet-polymerizable unsaturated bond, which may have a substituting group such as a methyl group, an ethyl group, etc. Specific examples of the unsaturated group R^(a) include a vinyl group, an allyl group, a methacryloxy group, an aminopropyl group, a glycidoxy group, an alkenyl group and a propargyl group. R^(b) is an organic group, which may be the same as or different from R^(a). Specific examples of the alkoxy group R^(b)O include a methoxy group, an ethoxy group, a propoxy group, a butoxy group, an isopropoxy group and an s-butoxy group.

Specific examples of the unsaturated alkoxysilane monomers include trimethoxyvinylsilane, triethoxyvinylsilane, allyltrimethoxysilane, allyltriethoxysilane, tributoxyvinylsilane, tripropoxyvinylsilane, allyltributoxysilane, allyltripropoxysilane, dimethoxydivinylsilane, diallyldimethoxysilane, diethoxydivinylsilane, diallyldiethoxysilane, trimethoxybutenylsilane, triethoxybutenylsilane, dibutenyldimethoxysilane, and di(3-butenyl)diethoxysilane.

An oligomer of the unsaturated alkoxysilane may be used as a silica-skeleton-forming compound. The unsaturated alkoxysilane oligomer also has at least one unsaturated group and at least one alkoxy group. The unsaturated alkoxysilane oligomer is preferably represented by the following general formula (2); Si_(m)O_(m−1)R^(a) _(2m+2-x)OR^(b) _(x)  (2), wherein R^(a) represents an organic group having an unsaturated bond and 2-10 carbon atoms, R^(b)O represents an alkoxy group having 1-4 carbon atoms, m represents an integer of 2-5, and x represents an integer of 4-7. Preferred examples of the unsaturated groups R^(a) and the alkoxy groups R^(b)O are the same as those in the above alkoxysilane monomers.

The number m of condensation is preferably 2-3. An oligomer whose number m of condensation is 5 or less can be easily obtained by the polymerization of the monomer using an acidic catalyst as described below. The number x of the alkoxy group is preferably 3-5. When the number x of the alkoxy group is less than 3, the hydrolysis and polycondensation of the alkoxysilane does not sufficiently proceed, making three-dimensional cross-linking difficult to occur, thereby making the formation of a wet gel too difficult. When the number x of the alkoxy group is more than 5, the percentage of the unsaturated group is too small, resulting in insufficient increase in mechanical strength by the polymerization. Specific examples of the unsaturated alkoxysilane oligomers include disilanes, trisilanes and tetrasilanes obtained by the condensation of the above unsaturated alkoxysilane monomers.

(b) Solvent

The solvent is preferably composed of water and alcohol. The alcohol is preferably methanol, ethanol, n-propyl alcohol, and isopropyl alcohol, particularly ethanol. How active the hydrolysis and polycondensation reaction are depends on a molar ratio of the monomer and/or oligomer of alkoxysilane or silsesquioxane (silica-skeleton-forming compound) to water. Though the water/alcohol molar ratio does not directly affect the hydrolysis and polycondensation reaction, it is preferably substantially 0.1-2. When the water/alcohol molar ratio is more than 2, the hydrolysis proceeds too quickly. When the water/alcohol molar ratio is less than 0.1, the hydrolysis of the silica-skeleton-forming compound does not sufficiently occur.

(c) Catalyst

A catalyst for the hydrolysis reaction is added to an aqueous solution of the silica-skeleton-forming compound. The catalyst may be acidic or basic. For instance, an efficient hydrolysis can be proceeded by condensing the silica-skeleton-forming compound monomer to an oligomer in an aqueous solution containing an acidic catalyst, and polymerizing the oligomer in a solution containing a basic catalyst. Specific examples of the acidic catalysts include hydrochloric acid, nitric acid and acetic acid. Specific examples of the basic catalysts include ammonia, amines, NaOH and KOH. Preferred examples of the amines include alcohol amines, and alkyl amines (methylamine, dimethylamine, trimethylamine, n-butylamine, and n-propylamine, etc.).

(d) Formulation

The silica-skeleton-forming compound is preferably dissolved in the solvent, such that a molar ratio of the solvent to alkoxysilane is 3-100. When the molar ratio is less than 3, the degree of polymerization of the alkoxysilane is too high. When the molar ratio exceeds 100, the degree of polymerization of the alkoxysilane becomes too low. A catalyst/alkoxysilane molar ratio is preferably 1×10⁻⁷ to 1×10⁻¹, more preferably 1×10⁻² to 1×10⁻¹. When the molar ratio is less than 1×10⁻⁷, the hydrolysis of the alkoxysilane does not occur sufficiently. Even at a molar ratio of more than 1×10⁻¹, increased catalytic effects cannot be obtained. A water/alkoxysilane molar ratio is preferably 0.5-20, more preferably 5-10.

(e) Aging

A solution containing the silica-skeleton-forming compound condensed by hydrolysis is left to stand or slowly stirred for aging at 25-90° C. for about 20-60 hours. Gelation proceeds by aging, to form a wet gel containing silicon oxide.

(i-2) Substitution of Dispersing Medium

A dispersing medium of the wet gel influences a surface tension and/or a contact angle of a solid phase to a liquid phase, which accelerate or retard aging, an extent of surface modification in the organic modification step, and an evaporation rate of the dispersing medium in the later-described coating step. The dispersing medium contained in the gel can be substituted by another dispersing medium by repeating an operation of pouring another dispersing medium into the gel, vibrating the gel and conducting decantation. The substitution of the dispersing medium may be conducted before or after an organic modification reaction, though it is preferably conducted before the organic modification reaction to reduce the number of steps.

Specific examples of the substituting dispersing media include ethanol, methanol, propanol, butanol, pentane, hexane, heptane, cyclohexane, toluene, acetonitrile, acetone, dioxane, methyl isobutyl ketone, propylene glycol monomethyl ether, ethylene glycol monomethyl ether, and ethyl acetate. These dispersing media may be used alone or in combination.

The preferred substituting dispersing media are ketones. Substitution with a ketone solvent before the later-described ultrasonic treatment step makes it possible to obtain a well-dispersible, organically modified, silica-containing sol. Because the ketone solvent has excellent affinity for silica (silicon oxide) and organically modified silica, organically modified silica is well dispersed in the ketone solvent. The preferred ketone solvent has a boiling point of 60° C. or higher. Ketones having boiling points of lower than 60° C. are evaporated too much in the later-described ultrasonic irradiation step. For instance, acetone used as a dispersing medium is much evaporated during the ultrasonic irradiation, resulting in difficulty in controlling the concentration of the dispersion. Acetone is quickly evaporated in the coating step, too, failing to keep a sufficient coating time. It is further known that acetone is harmful to humans, unpreferable for the health of an operator.

Particularly preferred as the ketone solvent is unsymmetrical ketone having different groups on both sides of a carbonyl group. Because nonsymmetrical ketone has a large polarity, it has excellent affinity particularly for silica and organically modified silica. The organically modified silica preferably has a particle size of 200 nm or less in the dispersion. When the particle size of the organically modified silica is more than 200 nm, it is difficult to form a silica aerogel coating having a substantially smooth surface.

The ketone may have an alkyl or aryl group. The preferred alkyl group has about 1-5 carbon atoms. Specific examples of the ketone solvents include methyl isobutyl ketone, ethyl isobutyl ketone, and methyl ethyl ketone.

(i-3) Organic Modification

An organic-modifying agent solution is added to the wet gel, so that hydrophilic groups such as a hydroxyl group, etc. at the end of silicon oxide constituting the wet gel are substituted by hydrophobic organic groups.

(a) Organic-Modifying Agents

(a-1) Saturated Organic-Modifying Agents

The preferred saturated organic-modifying agent is any of compounds represented by the following formulae (3)-(8); R^(c) _(p)SiCl_(q)  (3), R^(c) ₃SiNHSiR^(c) ₃  (4), R^(c) _(p)Si(OH)_(q)  (5), R^(c) ₃SiOSiR^(c) ₃  (6), R^(c) _(p)Si(OR^(b))_(q)  (7), and R^(c) _(p)Si(OCOCH₃)_(q)  (8), wherein p represents an integer of 1-3, q represents an integer of 1-3 satisfying the condition of q=4−p, R^(b)O represents an alkoxy group having 1-4 carbon atoms, and R^(c) represents hydrogen, a substituted or unsubstituted alkyl group having 1-18 carbon atoms, or a substituted or unsubstituted aryl group having 5-18 carbon atoms, or a mixture thereof.

Specific examples of the saturated organic-modifying agents include triethylchlorosilane, trimethylchlorosilane, diethyldichlorosilane, dimethyldichlorosilane, acetoxytrimethylsilane, acetoxysilane, diacetoxydimethylsilane, methyltriacetoxysilane, phenyltriacetoxysilane, diphenyldiacetoxysilane, trimethylethoxysilane, trimethylmethoxysilane, 2-trimethylsiloxy pent-2-en-4-one, N-(trimethylsilyl)acetamide, 2-(trimethylsilyl)acetate, N-(trimethylsilyl)imidazole, trimethylsilyl propiolate, nonamethyltrisilazane, hexamethyldisilazane, hexamethyldisiloxane, trimethylsilanol, triethylsilanol, triphenylsilanol, t-butyldimethylsilanol, diphenylsilanediol, etc.

(a-2) Unsaturated, Organic-Modifying Agents

Using the unsaturated organic-modifying agent, a silica aerogel coating with excellent toughness can be obtained even when a small amount of a binder is added. Preferred examples of the unsaturated organic-modifying agents are represented by the following formulae (9)-(14); R^(d) _(p)SiCl_(q)  (9), R^(d) ₃SiNHSiR^(d) ₃  (10), R^(d) _(p)Si(OH)_(q)  (11) R^(d) ₃SiOSiR^(d) ₃  (12), R^(d) _(p)Si(OR^(d))_(q)  (13), R^(d) _(p)Si(OCOCH₃)_(q)  (14), wherein p represents an integer of 1-3, q represents an integer of 1-3 meeting the condition of q=4−p, and R^(d) represents an organic group having an ultraviolet-polymerizable, unsaturated bond and 2-10 carbon atoms. The unsaturated group R^(d) may have a methyl group, an ethyl group, etc. Examples of the unsaturated group R^(d) include a vinyl group, an allyl group, a methacryloxy group, an aminopropyl group, a glycidoxy group, an alkenyl group, and a propargyl group. The unsaturated organic-modifying agent may be used alone or in combination. The unsaturated organic-modifying agent may be combined with the saturated organic-modifying agent.

The unsaturated organic-modifying agent is preferably unsaturated chlorosilane, more preferably unsaturated monochlorosilane having three unsaturated groups. Specific examples of the unsaturated organic-modifying agents include triallylchlorosilane, diallyldichlorosilane, triacetoxyallylsilane, diacetoxydiallylsilane, trichlorovinylsilane, dichlorodivinylsilane, triacetoxyvinylsilane, diacetoxydiallylsilane, trimethoxybutenylsilane, triethoxybutenylsilane, dibutenyldimethoxysilane, dibutenyldiethoxysilane, etc.

(b) Organic Modification Reaction

The organic-modifying agent is preferably dissolved in a solvent such as hydrocarbons such as pentane, hexane, cyclohexane, heptane, etc.; ketones such as acetone, etc.; aromatic compounds such as benzene, toluene, etc. The organic modification is preferably conducted at 10-40° C., although variable depending on the type and concentration of the organic-modifying agent. When the organic-modifying temperature is lower than 10° C., the organic-modifying agent does not easily react with silicon oxide. When it is higher than 40° C., the organic-modifying agent easily reacts with other substances than silicon oxide. The solution is preferably stirred to avoid a distribution in temperature and concentration in the solution during the reaction. For instance, when the organic-modifying agent solution is a solution of triethylchlorosilane in hexane, holding at 10-40° C. for about 20-40 hours (for instance, 30 hours) sufficiently turns a silanol group to a silyl group.

(i-4) Ultrasonic Treatment

The ultrasonic treatment turns the organically modified silica gel or sol to be suitable for coating. In the case of the organically modified silica gel, the ultrasonic treatment dissociates a gel coagulated by an electric force or a van der Waals force, and destroys covalent bonds of silicon to oxygen, resulting in a dispersed gel. In the case of the sol, too, the ultrasonic treatment reduces the agglomeration of colloid particles. The ultrasonic treatment can be conducted in a dispersing apparatus using an ultrasonic vibrator. An ultrasonic radiation frequency is preferably 10-30 kHz, and an output is preferably 300-900 W.

The ultrasonic treatment time is preferably 5-120 minutes. Longer ultrasonic irradiation results in finer pulverization of clusters of the gel or the sol, resulting in less agglomeration. Accordingly, colloid particles of organically modified silicon oxide are almost in a single dispersion state in the silica-containing sol obtained by the ultrasonic treatment. When the ultrasonic treatment time is shorter than 5 minutes, the colloid particles are not sufficiently dissociated. Even if the ultrasonic treatment time were longer than 120 minutes, the dissociation of the colloid particles of the organically modified silicon oxide would not substantially change.

To form a silica aerogel coating having a porosity of 20-60% and a refractive index of 1.25-1.30, the ultrasonic radiation frequency is preferably 10-30 kHz, the output is preferably 300-900 W, and the ultrasonic treatment time is preferably 5-120 minutes.

A dispersing medium may be added to provide the silica-containing sol with appropriate concentration and fluidity. The dispersing medium may be added before the ultrasonic treatment, or after conducting the ultrasonic treatment to some extent. A mass ratio of the organically modified silicon oxide to the dispersing medium is preferably 0.1-20%. When the mass ratio of the organically modified silicon oxide to the dispersing medium is outside the range of 0.1-20%, a uniform thin layer cannot be formed easily.

The use of a sol containing silicon oxide colloid particles having nearly single dispersion can form an organically modified silica aerogel layer with small porosity. On the other hand, the use of a sol containing largely agglomerated colloid particles can form a silica aerogel layer with large porosity. Thus, the ultrasonic treatment time influences the porosity of the silica aerogel coating. The coating of the sol ultrasonic-treated for 5-120 minutes can provide the organically modified silica aerogel layer with a porosity of 20-60%.

(ii) Preparation of Ultraviolet-Curable Resin Solution

The ultraviolet-curable resin functioning as a binder for the organically modified silica preferably has compatibility with a dispersion of the organically modified silica. As long as solvents can dissolve the ultraviolet-curable resin and are compatible with the organically modified silica dispersion, they are not restricted. Accordingly, they may be properly selected from those described above as the substituting dispersion media for the organically modified silica dispersion.

The ultraviolet-curable resin has a refractive index of preferably 1.5 or less, more preferably 1.3-1.4 after curing. Using an ultraviolet-curable resin having a refractive index of 1.5 or less after curing, a silica aerogel coating having a refractive index of 1.2-1.3 can be formed. Ultraviolet-curable, amorphous fluororesins preferably have a refractive index of 1.5 or less and excellent transparency. Specific examples of the ultraviolet-curable, amorphous fluororesins include fluoroolefin copolymers, fluorine-containing cycloaliphatic polymers, fluoroacrylate copolymers, etc.

An example of the fluoroolefin copolymer comprises 37-48% by mass of tetrafluoroethylene, 15-35% by mass of vinylidene fluoride, and 26-44% by mass of hexafluoropropylene.

Polymers having a fluorine-containing cycloaliphatic structure include those obtained by polymerizing monomers having a fluorine-containing cycloaliphatic structure, and those obtained by the ring-forming polymerization of fluorine-containing monomers having at least two polymerizable double bonds. The polymers obtained by the polymerization of monomers having a fluorine-containing ring structure are described in JP 63-18964 B, etc. They are obtained by the homo-polymerization of monomers having a fluorine-containing ring structure, such as perfluoro(2,2-dimethyl-1,3-dioxole), etc., or by their copolymerization with radically polymerizable monomers such as tetrafluoroethylene, etc.

The polymers obtained by the ring-forming polymerization of fluorine-containing monomers having at least two polymerizable double bonds are described in JP 63-238111 A, JP 63-238115 A, etc. They are obtained by the ring-forming polymerization of monomers such as perfluoro(allyl vinyl ether), perfluoro(butenyl vinyl ether), etc., or by their copolymerization with radically polymerizable monomers such as tetrafluoroethylene, etc. Examples of the copolymers include those obtained by the copolymerization of monomers having a fluorine-containing ring structure, such as perfluoro(2,2-dimethyl-1,3-dioxole), etc., with fluorine-containing monomers having at least two polymerizable double bonds, such as perfluoro(allyl vinyl ether), perfluoro(butenyl vinyl ether), etc.

The binder may be made of a resin other than the fluororesin, or a combination of the fluororesin and the other resin. The resins other than the fluororesin may be acrylic resins, silicone resins, epoxy resins or urethane resins.

(iii) Preparation of Coating Liquid

The coating liquid comprises the organically modified silica, one or more ultraviolet-curable resins, and a photo-polymerization initiator. The coating liquid can be obtained by (a) mixing a dispersion containing the organically modified silica with a solution containing the ultraviolet-curable resin and the photo-polymerization initiator, (b) mixing a dispersion containing the organically modified silica and the photo-polymerization initiator with a solution containing the ultraviolet-curable resin, (c) mixing a dispersion containing the organically modified silica and the photo-polymerization initiator with a solution containing the ultraviolet-curable resin and the photo-polymerization initiator, or (d) adding the photo-polymerization initiator after a dispersion containing the organically modified silica and a solution containing the ultraviolet-curable resin are mixed. The percentage of the organically modified silica in the dispersion before mixing is preferably 0.1-20% by mass per the dispersing medium as described above. When the binder is a fluoroolefin copolymer, the concentration of the copolymer is preferably 0.5-2.0% by mass.

The dispersion of organically modified silica and the ultraviolet-curable resin solution are mixed preferably such that a volume ratio of the organically modified silica to the ultraviolet-curable resin is 9:1-1:9 in the coating liquid. When the volume ratio of the ultraviolet-curable resin is more than 90% in the coating liquid, the pores of the silica aerogel are filled with the resin, resulting in the silica aerogel coating with too high a refractive index. When the volume ratio of the ultraviolet-curable resin is less than 10%, a binder ratio is too low to provide the silica aerogel coating with toughness.

The photo-polymerization initiator is added to such an extent that the ultraviolet-curable resin, or the ultraviolet-curable resin and the unsaturated groups of the organically modified silica can be polymerized, in an ultraviolet irradiation step described later. The photo-polymerization initiator may be added to the ultraviolet-curable resin solution and/or the dispersion of organically modified silica in advance, or after they are mixed. The amount of the photo-polymerization initiator is preferably 1-15% by mass per the coating liquid on a solid basis.

Specific examples of the photo-polymerization initiators include benzoin and its derivatives such as benzoin methyl ether, benzoin isopropyl ether, benzoin isobutyl ether, etc.; benzyl derivatives such as benzyl dimethyl ketal, etc.; alkyl phenones such as acetophenone, 2,2-dimethoxy-2-phenylacetophenone, 2,2-diethoxy2-phenylacetophenone, 1,1-dichloracetophenone, 1-hydroxycyclohexyl phenyl ketone, 2-methyl-1-[4-(methylthio)phenyl]-2-morpholinopropane-1-on, etc.; anthraquinone and its derivatives such as 2-methylanthraquinone, 2-chloroanthraquinone, 2-ethylanthraquinone, 2-t-butylanthraquinone, etc.; thioxanthone and its derivatives such as 2,4-dimethylthioxanthone, 2-chlorothioxanthone, etc.; benzophenone and its derivatives such as N,N-dimethylamino benzophenone, etc.

(iv) Coating

Examples of wet-coating methods include a spray-coating method, a spin-coating method, a dip-coating method, a flow-coating method and a bar-coating method. The preferred coating method is a spray-coating method, which can form a layer with uniform thickness. When the coating liquid is applied to a substrate, a dispersing medium is evaporated to form a layer composed of the organically modified silica, the ultraviolet-curable resin and the photo-polymerization initiator.

(v) Drying

Because the coating liquid contains a volatile solvent, it may be spontaneously dried, but its drying may be accelerated by heating at 50-100° C. Although the organically modified silica aerogel layer has a porosity reduced by the shrinkage of the gel due to capillary pressure during the evaporation of the dispersing medium, the porosity is recovered by a springback phenomenon after the completion of evaporation. Thus, the porosity of the dried, organically modified silica aerogel layer is substantially as large as the original one of the gel network. The shrinkage of a silica gel network and the springback phenomenon are described in U.S. Pat. No. 5,948,482 in detail.

(vi) Ultraviolet Irradiation

Ultraviolet rays are irradiated to the coating to polymerize the ultraviolet-curable resin, or the ultraviolet-curable resin and the unsaturated groups of the organically modified silica. Using an ultraviolet irradiation apparatus, the coating is preferably subjected to ultraviolet irradiation at about 50-10000 mJ/cm². The ultraviolet irradiation time is preferably about 1-30 seconds when the silica aerogel coating is as thick as about 10-2000 nm, although variable depending on the coating thickness.

(vii) Baking

The coating is preferably baked at 50-150° C. The baking removes a solvent from the layer and a hydroxyl group, etc. from the surface, thereby strengthening the coating. Because decomposition does not substantially occur at a baking temperature of about 50-150° C., the baked silica aerogel coating has a cured resin formed by the polymerization of the ultraviolet-curable resin or the ultraviolet-curable resin and the unsaturated groups of the organically modified silica.

(4) Substrate

The refractive index of the substrate 3 is 1.60-1.95, preferably 1.65-1.80, in a wavelength range of 400-700 nm. Because the first anti-reflection coating 1 exhibits an excellent anti-reflection function to a substrate 3 having a refractive index of 1.60-1.95, it is effective to reduce the size of an exchange lens unit. Specific examples of materials for the substrate 3 include optical glass such as BaSF2, SF5, LaF2, LaSF09, LaSF01, LaSF016, etc.

(5) Reflectance

The first anti-reflection coating 1 formed on the substrate 3 has reflectance of preferably 0.5% or less, more preferably 0.4% or less, to incident light at 0° in a wavelength range of 450-600 nm, and reflectance of preferably 1.0% or less, more preferably 0.95% or less, to incident light at 300 in a wavelength range of 400-650 nm.

[2] Second Anti-Reflection Coating

The second anti-reflection coating 1 according to another embodiment of the present invention is the same as the first anti-reflection coating except for the refractive index and optical thickness of each layer. Namely, in a wavelength range of 400-700 nm,

-   -   the substrate has a refractive index of 1.50-1.70,     -   the first layer 11 has an optical thickness of 24.5-200.0 nm,     -   the second layer 12 has a refractive index of 1.93-2.25 and an         optical thickness of 24.5-50.5 nm,     -   the third layer 13 has a refractive index of 1.33-1.50 and an         optical thickness of 14.0-30.0 nm,     -   the fourth layer 14 has a refractive index of 2.00-2.16 and an         optical thickness of 131.5-200.5 nm,     -   the fifth layer 15 has a refractive index of 1.33-1.50 and an         optical thickness of 20.0-31.5 nm,     -   the sixth layer 16 has a refractive index of 2.04-2.17 and an         optical thickness of 50.0-62.5 nm, and     -   the seventh layer 17 has an optical thickness of 122.5-142.5 nm.

The refractive index of the first layer 11 is preferably 1.57-1.72, more preferably 1.63-1.67. The first layer 11 preferably has an optical thickness of 30.0-200.0 nm. The second layer 12 preferably has an optical thickness of 30.0-45.0 nm and a refractive index of 2.02-2.20. The third layer 13 preferably has an optical thickness of 20.0-28.0 nm and a refractive index of 1.36-1.47. The fourth layer 14 preferably has an optical thickness of 150.0-183.0 nm and a refractive index of 2.00-2.15. The fifth layer 15 preferably has an optical thickness of 22.0-30.0 nm and a refractive index of 1.36-1.47. The sixth layer 16 preferably has an optical thickness of 50.0-60.0 nm and a refractive index of 2.05-2.15. The refractive index of the seventh layer 17 is preferably 1.23-1.32, more preferably 1.26-1.29. The seventh layer preferably has an optical thickness of 125.0-138.0 nm.

The refractive index of the substrate 3, on which the second anti-reflection coating 1 is formed, is 1.50-1.70, preferably 1.51-1.60, in a wavelength range of 400-700 nm. Because the second anti-reflection coating 1 has an excellent anti-reflection function to the substrate 3 having a refractive index of 1.50-1.70, it is effective to reduce the size of an exchange lens unit. Specific examples of materials for the substrate 3 include optical glass such as LF5, BK7, BAK1, BAK2, K3, PSK2, SK4, SK5, SK7, SK11, SK12, SK14, SK15, SK16, SK18, KF3, SK6, SK8, BALF2, SSK5, LLF1, LLF2, LLF6, BAF10, BAF11, BAF12, F1, F5, F8, F16, SF2, SF7, KZF2, KZF5, LAK11, LAK12, etc.

The second anti-reflection coating 1 formed on the substrate 3 has reflectance of preferably 0.3% or less, more preferably 0.26% or less, to incident light at 0° in a wavelength range of 450-600 nm.

[3] Fluororesin Layer

As shown in FIG. 2, a fluororesin layer 18 having water repellency or water/oil repellency (simply called “water/oil repellency”) may be formed on the seventh layer 17. The fluororesins are not particularly restricted as long as they are colorless and transparent, but they are preferably fluorine-containing polymers, fluorinated pitch, or organic-inorganic hybrid polymers.

The fluorine-containing polymers are preferably fluorine-containing olefinic polymers or copolymers, such as polytetrafluoroethylene (PTFE), tetraethylene-hexafluoropropylene copolymers (PFEP), ethylene-tetrafluoroethylene copolymers (PETFE), tetrafluoroethylene-perfluoroalkyl vinyl ether copolymers (PFA), ethylene-chlorotrifluoroethylene copolymers (PECTFE), tetrafluoroethylene-hexafluoropropylene-perfluoroalkyl vinyl ether copolymers (PEPE), polychlorotrifluoroethylene (PCTFE), polyvinylidene fluoride (PVDF), polyvinyl fluoride (PVF), etc. Commercially available fluorine-containing polymers may be, for instance, “OPSTAR” available from JSR Corporation, “CYTOP” available from Asahi Glass Co., Ltd.

The fluorine-containing organic-inorganic hybrid polymers may be organic silicon polymers having fluorocarbon groups, which may be polymers obtained by the hydrolysis of fluorine-containing silane compounds. The fluorine-containing silane compounds may be compounds represented by the following formula (15): CF₃(CF₂)_(a)(CH₂)₂SiR_(b)X_(c)  (15), wherein R is an alkyl group, X is an alkoxyl group or a halogen atom, a is an integer of 0-7, b is an integer of 0-2, c is an integer of 1-3, and b+c=3. Specific examples of the compounds represented by the formula (15) include CF₃(CH₂)₂Si(OCH₃)₃, CF₃(CH₂)₂SiCl₃, CF₃(CF₂)₅(CH₂)₂Si(OCH₃)₃, CF₃(CF₂)₅(CH₂)₂SiCl₃, CF₃(CF₂)₇(CH₂)₂Si(OCH₃)₃, CF₃(CF₂)₇(CH₂)₂SiCl₃, CF₃(CF₂)₇(CH₂)₃SiCH₃(OCH₃)₂, CF₃(CF₂)₇(CH₂)₂SiCH₃Cl₂, etc. Examples of commercially available organic silicon polymers include Novec EGC-1720 available from Sumitomo 3M Ltd., XC98-B2472 available from GE Toshiba Silicone Co., Ltd., X71-130 available from Shin-Etsu Chemical Co., Ltd., etc.

The fluororesin layer 18 is as thick as preferably 0.4-100 nm. When the thickness of the fluororesin layer is less than 0.4 nm, sufficient water/oil repellency cannot be obtained. On the other hand, with the fluororesin layer thicker than 100 nm, the anti-reflection coating has deteriorated transparency and changed optical properties. The refractive index of the fluororesin layer is preferably 1.5 or less, more preferably 1.45 or less. Although the fluororesin layer may be formed by a vacuum vapor deposition method, it is preferably formed by a wet method such as a sol-gel method.

The present invention will be explained in further detail by Examples below without intention of restricting the present invention thereto.

Example 1

An anti-reflection coating 1 having the layer structure shown in Table 1 was produced by the following steps. The refractive index of each layer is to light having a wavelength of 550 nm.

[1] Formation of First to Sixth Layers

Using the apparatus shown in FIG. 13, the first to sixth layers shown in Table 1 were formed on an optical lens of LaSF01 by an electron-beam vacuum vapor deposition method at an initial degree of vacuum of 1.2×10⁻⁵ Torr and a substrate temperature of 230° C.

[2] Formation of Seventh Layer

A silica aerogel layer as the seventh layer was formed by a sol-gel method comprising the following steps.

(2-i) Preparation of Wet Silica Gel

After 5.21 g of tetraethoxysilane and 4.38 g of ethanol were mixed, 0.4 g of hydrochloric acid (0.01 N) was added, and stirring was conducted for 90 minutes. With 44.3 g of ethanol and 0.5 g of ammonia water (0.02 N) added, stirring was conducted for 46 hours, and then this mixed solution was aged at 60° C. for 46 hours to obtain a wet silica gel.

(2-ii) Preparation of Dispersion of Organically Modified Silica

The wet silica gel was mixed with ethanol, vibrated for 10 hours, and then decanted to remove unreacted materials, and to change the wet-gel-dispersing medium to ethanol. With methyl isobutyl ketone (MIBK) added, the ethanol-dispersed wet gel was vibrated for 10 hours, and then decanted to change the dispersing medium from ethanol to MIBK.

The wet silica gel was mixed with a solution of trimethylchlorosilane in MIBK (concentration: 5% by volume) and stirred for 30 hours to organically modify silicon oxide at ends. The resultant organically modified wet silica gel was washed with MIBK by vibration for 24 hours and decantation.

MIBK was added to the organically modified wet silica gel to a concentration of 3% by mass, and ultrasonic irradiation (20 kHz, 500 W) was conducted for 20 minutes to turn the wet silica gel to a sol-like, organically modified silica (dispersion of the organically modified silica).

(2-iii) Preparation of Coating Liquid

The dispersion of the organically modified silica prepared in the step (2-ii) was mixed with a low-refractive-index, ultraviolet-curable resin solution (“AR100” available from Daikin Industries, Ltd.) at a volume ratio of 9:1 to prepare a coating liquid containing the organically modified silica.

(2-iv) Spin-Coating

The coating liquid containing the organically modified silica was applied to the sixth layer by a spin-coating method, subjected to ultraviolet irradiation at 1500 mJ/cm² using an ultraviolet irradiation apparatus available from Fusion Systems, and baked at 150° C. for 1 hour to form a silica aerogel coating, in which the ultraviolet-curable resin was polymerized, and the silica sol was hydrolyzed and polycondensed to have organically modified chains. The thickness of the silica aerogel layer is shown in Table 1.

TABLE 1 Refractive Optical No. Material Index Thickness (nm) Substrate LaSF01 1.790 — First Layer Al₂O₃ 1.650 75.0 Second Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 47.8 Third Layer MgF₂ 1.380 32.9 Fourth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 235.9 Fifth Layer MgF₂ 1.380 20.9 Sixth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 37.9 Seventh Layer Silica Aerogel 1.270 123.1 Medium Air 1.000 —

Example 2

An anti-reflection coating having the layer structure shown in Table 2 was formed in the same manner as in Example 1.

TABLE 2 Refractive Optical No. Material Index Thickness (nm) Substrate LaSF01 1.790 — First Layer Al₂O₃ 1.650 85.0 Second Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 40.0 Third Layer MgF₂ 1.380 28.0 Fourth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 215.0 Fifth Layer MgF₂ 1.380 25.0 Sixth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 35.0 Seventh Layer Silica Aerogel 1.270 115.0 Medium Air 1.000 —

Example 3

An anti-reflection coating having the layer structure shown in Table 3 was formed in the same manner as in Example 1.

TABLE 3 Refractive Optical No. Material Index Thickness (nm) Substrate LaSF01 1.790 — First Layer Al₂O₃ 1.650 75.0 Second Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 47.8 Third Layer MgF₂ 1.380 32.9 Fourth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 230.0 Fifth Layer MgF₂ 1.380 20.9 Sixth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 37.9 Seventh Layer Silica Aerogel 1.270 137.5 Medium Air 1.000 —

Example 4

An anti-reflection coating having the layer structure shown in Table 4 was formed in the same manner as in Example 1.

TABLE 4 Refractive Optical No. Material Index Thickness (nm) Substrate LaSF01 1.790 — First Layer Al₂O₃ 1.650 100.0 Second Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 37.5 Third Layer MgF₂ 1.380 37.5 Fourth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 245.0 Fifth Layer MgF₂ 1.380 18.8 Sixth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 32.5 Seventh Layer Silica Aerogel 1.270 123.1 Medium Air 1.000 —

Example 5

An anti-reflection coating having the layer structure shown in Table 5 was formed in the same manner as in Example 1.

TABLE 5 Refractive Optical No. Material Index Thickness (nm) Substrate LaSF01 1.790 — First Layer Al₂O₃ 1.650 75.0 Second Layer ZrO₂ + TiO₂ 2.110 47.8 Third Layer SiO₂ 1.450 32.9 Fourth Layer ZrO₂ + TiO₂ 2.110 235.9 Fifth Layer SiO₂ 1.450 20.9 Sixth Layer ZrO₂ + TiO₂ 2.110 37.9 Seventh Layer Silica Aerogel 1.270 123.1 Medium Air 1.000 —

Example 6

An anti-reflection coating having the first to seventh layers shown in Table 6 was formed on an optical lens of LaSF01 in the same manner as in Example 1, immersed in a coating liquid comprising 3 g of a silicone-type fluororesin (“X71-130” available from Shin-Etsu Chemical Co., Ltd.) and 60 g of hydrofluoroether, lifted out of the coating liquid at 300 mm/minute, and dried at room temperature for 24 hours to obtain a fluororesin layer.

TABLE 6 Refractive Optical No. Material Index Thickness (nm) Substrate LaSF01 1.790 — First Layer Al₂O₃ 1.650 75.0 Second Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 47.8 Third Layer MgF₂ 1.380 32.9 Fourth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 235.9 Fifth Layer MgF₂ 1.380 20.9 Sixth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 37.9 Seventh Layer Silica Aerogel 1.270 123.1 Eighth Layer Fluororesin Layer 1.400 35.0 Medium Air 1.000 —

Example 7

An anti-reflection coating having the layer structure shown in Table 7 was formed on an optical lens of LF5 in the same manner as in Example 1.

TABLE 7 Refractive Optical No. Material Index Thickness (nm) Substrate LF5 1.584 — First Layer Al₂O₃ 1.650 81.1 Second Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 39.7 Third Layer MgF₂ 1.380 23.1 Fourth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 157.7 Fifth Layer MgF₂ 1.380 25.0 Sixth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 56.5 Seventh Layer Silica Aerogel 1.270 131.3 Medium Air 1.000 —

Example 8

An anti-reflection coating having the layer structure shown in Table 8 was formed in the same manner as in Example 7.

TABLE 8 Refractive Optical No. Material Index Thickness (nm) Substrate LF5 1.584 — First Layer Al₂O₃ 1.650 200.0 Second Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 37.5 Third Layer MgF₂ 1.380 25.0 Fourth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 182.5 Fifth Layer MgF₂ 1.380 22.5 Sixth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 50.0 Seventh Layer Silica Aerogel 1.270 125.0 Medium Air 1.000 —

Example 9

An anti-reflection coating having the layer structure shown in Table 9 was formed in the same manner as in Example 7.

TABLE 9 Refractive Optical No. Material Index Thickness (nm) Substrate BK7 1.518 — First Layer Al₂O₃ 1.650 81.1 Second Layer ZrO₂ + TiO₂ 2.110 39.7 Third Layer SiO₂ 1.462 23.1 Fourth Layer ZrO₂ + TiO₂ 2.110 157.7 Fifth Layer SiO₂ 1.462 25.0 Sixth Layer ZrO₂ + TiO₂ 2.110 56.5 Seventh Layer Silica Aerogel 1.270 131.3 Medium Air 1.000 —

Example 10

An anti-reflection coating having the first to seventh layers shown in Table 10 was formed on an optical lens of LF5 in the same manner as in Example 7, and then the same fluororesin layer as in Example 6 was formed.

TABLE 10 Refractive Optical No. Material Index Thickness (nm) Substrate LF5 1.584 — First Layer Al₂O₃ 1.650 81.1 Second Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 39.7 Third Layer MgF₂ 1.380 23.1 Fourth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 157.7 Fifth Layer MgF₂ 1.380 25.0 Sixth Layer Ta₂O₅ + Y₂O₃ + Pr₆O₁₁ 2.050 56.5 Seventh Layer Silica Aerogel 1.270 131.3 Eighth Layer Fluororesin Layer 1.400 35.0 Medium Air 1.000 —

Comparative Example 1

An anti-reflection coating having the layer structure shown in Table 11 was formed in the same manner as in Example 1 except for using MgF₂ for the seventh layer.

TABLE 11 Refractive Optical No. Material Index Thickness (nm) Substrate LaSF01 1.790 — First Layer Al₂O₃ 1.650 171.75 Second Layer ZrO₂ + TiO₂ 2.110 25.50 Third Layer MgF₂ 1.380 36.00 Fourth Layer ZrO₂ + TiO₂ 2.110 108.25 Fifth Layer MgF₂ 1.380 23.25 Sixth Layer ZrO₂ + TiO₂ 2.110 89.00 Seventh Layer MgF₂ 1.380 134.50 Medium Air 1.000 —

Comparative Example 2

An anti-reflection coating having the layer structure shown in Table 12 was formed in the same manner as in Example 7 except for using MgF₂ for the seventh layer.

TABLE 12 Refractive Optical No. Material Index Thickness (nm) Substrate LF5 1.584 — First Layer Al₂O₃ 1.651 36.38 Second Layer Ta₂O₅ 2.097 24.25 Third Layer MgF₂ 1.389 37.34 Fourth Layer Ta₂O₅ 2.097 102.74 Fifth Layer MgF₂ 1.389 25.09 Sixth Layer Ta₂O₅ 2.097 82.84 Seventh Layer MgF₂ 1.389 134.32 Medium Air 1.000 —

FIGS. 3-8 show the spectral reflectance characteristics of the anti-reflection-coated optical lenses of Examples 1-5 and Comparative Example 1, which were measured by light in a wavelength range of 350-850 nm at incident angles of 0° and 30°. A medium in contact with the outermost layer was air. As shown in FIGS. 3-7, Examples 1-5 exhibited low reflectance to visible light in a wavelength range of 400-700 nm at any incident angles of 0° and 30°. On the other hand, as shown in FIG. 8, Comparative Example 1 exhibited reflectance higher than 0.5% near a wavelength of 560 nm when the incident angle was 0°.

FIGS. 9-12 show the spectral reflectance characteristics of the anti-reflection-coated optical lenses of Examples 7-9 and Comparative Example 2, which were measured by light in a wavelength range of 350-850 nm at an incident angle of 0°. A medium in contact with the outermost layer was air. As shown in FIGS. 9-11, Example 7-9 exhibited low reflectance in a visible wavelength range of 400-700 nm. On the other hand, as shown in FIG. 12, Comparative Example 2 exhibited reflectance higher than 0.3% near a wavelength of 480 nm.

Photographs taken with the optical lenses of Examples 1-10 had no flare and ghost, while those taken with the optical lenses of Comparative Examples 1 and 2 had flare and ghost.

EFFECT OF THE INVENTION

Because the anti-reflection coating of the present invention comprises an alumina-based, innermost layer and a porous, silica-based, outermost layer, as well as intermediate layers having controlled refractive indices and optical thickness, it has an excellent anti-reflection effect to visible light in a wavelength range of 400-700 nm even with as few as 7 layers in total, without suffering tarnish. The anti-reflection coating of the present invention having such feature is suitable for exchange lens units for single-lens reflex cameras, etc., providing photographs free from flare and ghost.

The present disclosure relates to subject matter contained in Japanese Patent Application No. 2007-337906 (filed on Dec. 27, 2007) and Japanese Patent Application No. 2008-003644 (filed on Jan. 10, 2008), which are expressly incorporated herein by reference in their entireties. 

1. An anti-reflection coating comprising first to seventh layers formed on a substrate in this order, said first layer being an alumina-based layer, said seventh layer being a porous, silica-based layer, and in a wavelength range of 400-700 nm, said substrate having a refractive index of 1.60-1.95, said first layer having an optical thickness of 37.5-112.5 nm, said second layer having a refractive index of 1.95-2.25 and an optical thickness of 35.5-60.0 nm, said third layer having a refractive index of 1.35-1.50 and an optical thickness of 24.5-41.5 nm, said fourth layer having a refractive index of 1.95-2.25 and an optical thickness of 210.5-250.0 nm, said fifth layer having a refractive index of 1.35-1.50 and an optical thickness of 12.5-32.5 nm, said sixth layer having a refractive index of 1.95-2.25 and an optical thickness of 27.5-45.0 nm, and said seventh layer having an optical thickness of 108.0-138.0 nm.
 2. The anti-reflection coating according to claim 1, wherein said second layer, said fourth layer and said sixth layer are made of at least one material selected from the group consisting of Ta₂O₅, ZrO₂, HfO₂, CeO₂, SnO₂, In₂O₃ and ZnO, and said third layer and said fifth layer are made of MgF₂ and/or SiO₂.
 3. The anti-reflection coating according to claim 1, wherein said first layer has a refractive index of 1.59-1.69.
 4. The anti-reflection coating according to claim 1, wherein said seventh layer having a refractive index of 1.25-1.30.
 5. The anti-reflection coating according to claim 1, which has reflectance of 0.5% or less to incident light at 0° in a wavelength range of 450-600 nm, and reflectance of 1.0% or less to incident light at 30° in a wavelength range of 400-650 nm.
 6. The anti-reflection coating according to claim 1, wherein said seventh layer is a silica aerogel layer.
 7. The anti-reflection coating according to claim 1, wherein a fluororesin layer as thick as 0.4-100 nm having water repellency or water/oil repellency is formed on said seventh layer.
 8. The anti-reflection coating according to claim 1, wherein said seventh layer is formed by a sol-gel method.
 9. An optical member having the anti-reflection coating recited in claim
 1. 10. An exchange lens unit comprising the optical member recited in claim
 9. 11. An imaging device comprising the optical member recited in claim
 9. 12. An anti-reflection coating comprising first to seventh layers formed on a substrate in this order, said first layer being an alumina-based layer, said seventh layer being a porous, silica-based layer, and in a wavelength range of 400-700 nm, said substrate having a refractive index of 1.50-1.70, said first layer having an optical thickness of 24.5-200.0 nm, said second layer having a refractive index of 1.93-2.25 and an optical thickness of 24.5-50.5 nm, said third layer having a refractive index of 1.33-1.50 and an optical thickness of 14.0-30.0 nm, said fourth layer having a refractive index of 2.00-2.16 and an optical thickness of 131.5-200.5 nm, said fifth layer having a refractive index of 1.33-1.50 and an optical thickness of 20.0-31.5 nm, said sixth layer having a refractive index of 2.04-2.17 and an optical thickness of 50.0-62.5 nm, and said seventh layer having a refractive index of 1.23-1.32 and an optical thickness of 122.5-142.5 nm.
 13. The anti-reflection coating according to claim 12, wherein said second layer, said fourth layer and said sixth layer are made of at least one material selected from the group consisting of Ta₂O₅, ZrO₂, HfO₂, CeO₂, SnO₂, In₂O₃ and ZnO, and said third layer and said fifth layer are made of MgF₂ and/or SiO₂.
 14. The anti-reflection coating according to claim 12, wherein said first layer has a refractive index of 1.57-1.72.
 15. The anti-reflection coating according to claim 12, which has reflectance of 0.3% or less to incident light at 0° in a wavelength range of 450-600 nm.
 16. The anti-reflection coating according to claim 12, wherein said seventh layer is a silica aerogel layer.
 17. The anti-reflection coating according to claim 12, wherein a fluororesin layer as thick as 0.4-100 nm having water repellency or water/oil repellency is formed on said seventh layer.
 18. The anti-reflection coating according to claim 12, wherein said seventh layer is formed by a sol-gel method.
 19. An optical member having the anti-reflection coating recited in claim
 12. 20. An exchange lens unit comprising the optical member recited in claim
 19. 21. An imaging device comprising the optical member recited in claim
 19. 